Panel for a ball

ABSTRACT

Methods for manufacturing a panel for a ball, in particular for a soccer ball, as well as panels manufactured by these methods and balls with such panels. A method comprises the following steps: providing a carrier material having an outer side and an inner side within a mold having at least one first and at least one second mold part. Three-dimensionally molding an outer layer of the panel on the outer side of the carrier material within the mold. Three-dimensionally molding an inner layer of the panel on the inner side of the carrier material using at least the first mold part.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/167,630, filed May 27, 2016. This application isincorporated herein by reference in its entirety.

FIELD

Embodiments of the present invention relate to panels for a ball, inparticular for a soccer ball, a ball with such panels as well as amethod for manufacturing such panels.

BACKGROUND

Balls, in particular sports balls, such as soccer balls, often comprisea cover having a plurality of panels, which may be stitched to eachother, glued together or joined otherwise. Meanwhile panels are mostlymanufactured from plastics, but they may also comprise natural leather.

DE 102 55 092 B4 describes a method for manufacturing three-dimensionalpanels of a ball, wherein said panels comprise an outer material and asupport material.

Important factors when manufacturing panels are e.g. the aerodynamic andhaptic properties of the ball manufactured from the panels. Inparticular in the case of soccer balls, it has turned out that a surfaceof the ball which is too smooth may have a negative influence on theflying properties and, for example, may lead to a “fluttering” of theball. In addition, the surface of balls should provide sufficientfriction to prevent the ball from slipping, e.g. from the foot in thecase of a soccer ball, or from the hand etc. in the case of a handballor other balls. For this purpose, different approaches are known fromthe prior art to accordingly design the surfaces of balls or ofindividual panels.

DE 10 2009 016 287 B3 describes an inflatable ball, in particular asoccer ball, having an outer cover comprising a plurality of panels, thepanels being connected with each other by sutures and each panelcomprising at least one pseudo-suture which extends at least along apart of the outer surface of the panel.

Another factor to be considered when manufacturing panels for balls isthe optical design of the panels or the balls. For optically designingballs, the surface of panels or also of a fully assembled ball may, forexample, be printed or sprayed on. In this regard, however, the opticaldesigns are quickly deteriorated by abrasion under the influence ofkicks, impacts, hitting the ground etc.

U.S. Pat. No. 5,649,701 discloses panels for a ball with a transparentcover layer onto which further layers are laminated. U.S. Pat. No.8,602,927 B2 discloses cover panels for a ball which are heat bonded toa reinforcement material. Further balls with panels are disclosed inU.S. Pat. No. 7,066,853 B2 and U.S. Pat. No. 6,261,400 B1. U.S. Pat. No.8,454,348 B2 and U.S. Pat. No. 8,764,581 B2 disclose different methodsfor manufacturing balls without panels.

A disadvantage of the known panels is that for providing desiredoptical, haptic and aerodynamic properties, a plurality of separatelymanufactured elements are necessary. After having been manufactured,these separately manufactured elements are joined, e.g. laminated orbonded. As a result, manufacturing a panel requires a plurality ofmanufacturing apparatuses and different manufacturing steps, which makesproduction complex and expensive. Moreover, the separate elements oftenhave to be manually inserted into corresponding apparatuses or removedfrom them, so that the manufacture is also labor-intensive. By theplurality of separately manufactured and joined elements, also theconstructive design of the panels becomes more complicated, which maynegatively influence the endurance and durability of the ball.

Based on this prior art, it is an object of the present invention toprovide a simplified method for manufacturing panels, which neverthelessallows to advantageously influence the optical, haptic and/oraerodynamic properties of the panels and at the same time provide highdurability of the panels and the balls manufactured therefrom vis-à-visexternal influences.

BRIEF SUMMARY OF THE INVENTION

This object is at least partially achieved by a method for manufacturinga panel for a ball, in particular for a soccer ball. In an embodiment,the method comprises providing a carrier material having an outer sideand an inner side within a mold having at least one first and one secondmold part. On the outer side of the carrier material, an outer layer ofthe panel is three-dimensionally molded within the mold. In addition, onthe inner side of the carrier material an inner layer of the panel isthree-dimensionally molded using at least the first mold part.

The mentioned method enables manufacturing three-dimensionally moldedpanels for a ball with a minimum number of manufacturing steps.Separately molding a plurality of elements and subsequently attachingthe molded elements to each other is not necessary. Rather, the innerlayer and the outer layer of the panel are integrallythree-dimensionally molded in one manufacturing step at the carriermaterial. The inner or outer sides of the panel can thus be efficientlyprovided with the different desired properties. For example,three-dimensionally molding the outer layer and/or the inner layer onthe carrier material may be carried out by injection molding.

Generally, it is possible to dispense with the carrier material. Forexample, it would be possible to integrally three-dimensionally mold theinner layer and the outer layer of the panel directly adjacent to eachother. In this case, the inner and/or outer layer may for example beprovided as a foil or a textile material.

The inner layer may e.g. be optimized such that specific cushioning andbouncing properties are provided. The outer layer, on the other hand,may e.g. be aimed at providing a sealing which prevents moisture fromthe outside from entering and/or offers protection from abrasion. Byusing at least one mold part for molding the inner and the outer layer,it becomes possible to provide the panel with different desiredproperties on the inside and the outside, wherein the panel maysimultaneously remain in the mold during manufacture. A simpler andfaster manufacture is thus enabled, which may dispense with manualoperation. Furthermore, the panel manufacture may thus be quicklyadapted to individual customer wishes.

By manufacturing the multi-layer panel with at least one joint mold partfor several molding steps, the method according to embodiments of theinvention enables an efficient automated production process with shortproduction times. Thus, a high degree of flexibility regarding designand production is provided.

In addition, by integrally manufacturing the panels by means of thementioned method, waste can be avoided, as it is not necessary to cutseparately produced layers or elements to match each other. Rather, theinner and outer layers are molded into the desired three-dimensionalshape directly on a carrier material. Thus, cutting waste can beavoided. At most, it may be necessary to cut the carrier material, forexample after molding the inner and outer layer. However, cutting thecarrier material may be avoided as well if the carrier material isalready provided with fitting dimensions within the mold. Moreover, thecarrier material may be three-dimensionally molded already before it isprovided within the mold. Altogether, the panels may be manufactured ina more environmentally friendly and cost-saving manner. Furthermore, nosemi-finished materials are necessary for cutting the panels.Consequently, by the method according to embodiments of the invention,more efficient and sustainable manufacture of panels is enabled.

By the method according to embodiments of the invention, panels of anyshape may be individually manufactured. A panel of almost any outercontour and almost any cross-section may thus be produced by means ofthe method. The outer contour/cross-section of the panels ispredeterminable and adjustable by means of the mold parts. For example,the mold parts may comprise exchangeable inserts, for example ofsilicone and/or ceramic and/or metal, by means of which the cavities orindentations formed by the mold parts may be individually adapted. Thepanel manufacture may thus be adapted to individual customer wishes.

By integrally manufacturing the panel, the method according toembodiments of the invention can completely dispense with adhesives,bonding agents, or the like. No separate adhesives need to be applied tojoin the individual layers of the panel. The materials used for theindividual layers of the panel are compatible with each other and,according to some examples, may be joined solely by means of thermaland/or mechanical energy. Furthermore, it is also possible to join theused materials by means of chemical reactions. A bonding is enabled byaffinity of the used materials. However, should it be advantageous forthe panel to be manufactured, adhesives, bonding agents or the like maybe used alternatively.

By using an at least partially transparent outer layer, the carriermaterial may furthermore be used for providing the panel with a desiredoptical design protected from abrasion. For example, the carriermaterial may comprise a desired color. In addition, by means of asuitable combination of a carrier material and an at least partiallytransparent material for the outer layer, optical effects which appearthree-dimensional may be achieved, as explained later in more detail.

Moreover, it has turned out that by means of the described method,panels may be manufactured with suitable materials which are hardlyprone to wrinkling. This has the enormous advantage that ballsmanufactured with such panels do not have to be transported in theinflated state. Rather, they may be transported in a space-saving mannerin the deflated state. For example, they may be inflated only on site,e.g. in retail stores or at the end customer, without permanent wrinklesor cracks being caused by the transport in the deflated state. The ballsmay thus be delivered in a significantly more environmentally friendlyand cost-effective manner.

The method according to embodiments of the invention also allowsmanufacturing the panels independently of a ball bladder or a carcass.This way it is possible for the panels and the bladder or the carcass tobe manufactured at different locations and to be joined only at the endcustomer. Consequently, the panels may be individually delivered towhere they are needed.

The three-dimensionally molding the outer layer and the inner layer eachinclude three-dimensionally molding a material applied to the carriermaterial. Material for the outer layer and/or the inner layer may beapplied to the carrier material by e.g. injection molding andthree-dimensionally molded. Alternatively, the respective material mayalso be otherwise introduced into the mold, e.g. cast or inserted.

Three-dimensionally molding the inner and/or the outer layer may each becarried out at a certain temperature and/or a certain temperatureprofile. For example, at least one of the mold parts of the mold may beheated or cooled. This way the three-dimensionally molding may besupported by targeted heating or cooling of the respective material tobe molded. For example, heating may be performed prior to and/or duringthe three-dimensionally molding, and/or cooling may be performed afterthe three-dimensionally molding.

The inner layer may have a thickness of e.g. 1 mm to 15 mm or 4 mm to 10mm or approximately 7 mm. The outer layer may have a thickness of e.g.0.05 mm to 5 mm or 0.1 mm to 2 mm or approximately 0.5 mm. By means ofthe method according to embodiments of the invention, it is possible toindividually adapt the thickness of the inner layer or the thickness ofthe outer layer and tailor it to the respective requirements of the ballfor which the panels are intended to be used.

The carrier material may remain within the at least one first of the atleast two mold parts between the three-dimensionally molding the outerlayer and the three-dimensionally molding the inner layer. In the courseof this, the outer layer may be three-dimensionally molded prior to,after, simultaneously or at least partly simultaneously with the innerlayer. Accordingly, material for the inner layer may be applied to thecarrier material prior to, after, simultaneously or also at least partlysimultaneously with the material for the outer layer. By the carriermaterial remaining in the at least one mold part, efficientmanufacturing is enabled. A removal from a mold part (e.g. formanufacturing the inner layer) and a subsequent insertion into anothermold part (e.g. for manufacturing the outer layer) is no longerrequired.

The three-dimensionally molding the inner layer may be carried out suchthat the inner layer is enclosed by the carrier material at an outerface and at side faces of the inner layer. This way it can be ensuredthat the inner layer is enclosed by the carrier material on allsides—except its inner side, which may e.g. be intended for beingattached to a bladder for a ball. The inner layer may thus becomprehensively protected by the carrier material from externalinfluences such as moisture or friction. This may be achieved e.g. byproviding the carrier material with a three-dimensional shape, e.g. withan indentation on its inner side. The material for the inner layer maythen be inserted into said indentation and three-dimensionally moldedsuch that its outer face and its side faces are enclosed by the carriermaterial.

Arranging the carrier material around the outer and side faces of theinner layer furthermore enables the inner layer to be enclosed on allthese sides also by the outer layer arranged on the outer side of thecarrier material. In particular, this enables manufacturing a panelwhose inner layer is protected by the carrier material and the outerlayer both on the outer face and on the side faces. Fraying or tearingof the panel on its side faces may thus be strongly suppressed.

The three-dimensionally molding the outer layer may be carried out suchthat the inner layer is enclosed by the outer layer at an outer face andat side faces of the inner layer. As already explained, this enablesprotection of the panel by the outer layer both at the outer face and atthe side faces of the panel. Furthermore, it is enabled this way to joina plurality of panels at their side faces via the outer layer. Thematerial of the outer layer may be optimized for this purpose and enablea particularly good bonding, e.g. by means of infrared welding etc.

The inner layer may at least in part be molded by a third mold part,which is not used for the three-dimensionally molding the outer layer.For example, the at least one first mold part and at least one secondmold part may be used for molding the outer layer. Instead of the atleast one second mold part, at least one third mold part together withthe at least one first mold part may be used for molding the innerlayer. For example, the first and the second mold part may be designedsuch that they form a cavity for the three-dimensionally molding anouter layer, the cavity being designed such that an indentation isformed in the carrier material arranged under the outer layer. To thisend, the at least one second mold part may e.g. be formed as a dieelement which is pressed onto the first mold part. Alternatively oradditionally, the carrier material may be separately three-dimensionallymolded or already be provided three-dimensionally molded. The at leastone third mold part may be designed such that the indentation formed inthe carrier material is filled with material for the inner layer.Combining a “new” third mold part with the first mold part, within whichthe panel may remain, allows simplified manufacturing, which maynevertheless take account of different geometries of the outer and innerlayer of the panel. In particular, the inner face of the inner layer maybe designed such that it comprises an evenly curved surface, which isadapted to a curvature of a ball to which the panel is to be attached.

Material for the inner layer may be applied to the carrier materialthrough the third mold part. The third mold part may e.g. directly serveas a gate for injection molding, with flowable material being applied tothe carrier material through the third mold part. The third mold partmay comprise one or more openings. Therefore, the remaining mold partsdo not need to be designed for applying material for the inner layer.Instead, it may be sufficient that the third mold part used for thethree-dimensionally molding the inner layer is simultaneously alsodesigned for introducing the corresponding material.

The inner layer may comprise polyurethane or foamed polyurethane, inparticular expanded thermoplastic polyurethane. Polyurethane, inparticular foamed polyurethane or expanded thermoplastic polyurethaneenable providing good cushioning properties. Especially expandedthermoplastic polyurethane offers cushioning properties that areconstant over a large temperature range and do not noticeably decreaseover the lifetime of a ball. In general, polyurethane may be easilythree-dimensionally molded, e.g. by injection molding. Also expandedthermoplastic polyurethane, e.g. in the form of pellets, may be easilythree-dimensionally molded. In this regard, reference is made by way ofexample to patent applications DE 10 2012 206 094 and EP 2 649 896.Moreover, by using expanded thermoplastic polyurethane, thealready-explained low tendency of the panel to wrinkle is furtherreduced. In other examples, e.g. other foamed plastic materials may beused as well, e.g. foamed ethylene-vinyl acetates and/or other expandedplastic materials, e.g. expanded ethylene-vinyl acetates and/or expandedpolyether block amide. Furthermore, e.g. various PU systems may also beused for the inner layer, for example two-component PU systems. PUsystems are particularly well adaptable to different requirements.

Material for the outer layer may be applied to the carrier materialthrough the at least one first of the at least two mold parts. Similarlyas explained with regard to the optional third mold part for the innerlayer, the at least one first mold part may thus e.g. serve as a gatefor injection molding, wherein flowable material is applied to thecarrier material through the first mold part. The first mold part maycomprise one or more openings for this purpose. Therefore, the remainingmold parts do not need to be designed for applying material for theouter layer.

Generally it is possible to apply a plurality of different layers or aplurality of different outer layers to the carrier material through theat least one first mold part. It is conceivable, for example, tosuccessively apply different outer layers which differ with regard tothe materials used and/or the material properties. For this purpose, thefirst mold part may comprise openings at different locations throughwhich flowable material may be applied to the carrier material. It ispossible that the individual layers or outer layers only differ withregard to their color design. Alternatively, it is for example generallyalso possible to replace the first mold part with a further mold part inorder to apply further layers or outer layers.

Furthermore, it is possible to insert a structure element into the moldbefore the three-dimensionally molding the outer layer. For example,such a structure element may be inserted into the first mold part beforeapplying the flowable material. The structure element may be surroundedby the flowable material applied to the carrier material through thefirst mold part and thus be embedded in the outer layer. The structureelement may, for example, be a textile element, for example a knittedfabric, a weft-knitted fabric, a warp-knitted fabric, a mesh and/or awoven fabric.

Alternatively, it is also possible that the structure element is notembedded in the outer layer but used for flexibly creating textures orundercuts in the outer layer. In this process, an outer contour of thestructure element predetermines the texture of the outer layer. Such astructure element may, for example, be formed of ceramic, siliconeand/or metal. The properties of the structure element are such that itis easily possible to demold the outer layer after thethree-dimensionally molding the same. Such structure elements may bedesigned as desired in order to flexibly introduce desired textures intothe outer layer. In the same manner, such structure elements may be usedin connection with applying the inner layer or in connection with thethird mold part.

The outer layer may comprise polyurethane, in particular transparentpolyurethane or polyurethane which is at least partially transparent forvisible light. The polyurethane of the outer layer may particularly beoptimized with respect to providing high abrasion resistance and/or aparticular static friction, which transparent polyurethanes areparticularly also suitable for. In particular, the use of transparentpolyurethane furthermore enables optically designing the panel by meansof the carrier material, with the optical design of the panelsimultaneously being protected from abrasion. By an interaction betweenthe transparent outer layer and the carrier material, optical effectswhich appear three-dimensional may also be provided in this process. Forexample, the outer layer and/or the carrier material may also comprisetextures apart from a corresponding color design of the outer layerand/or the carrier material. Furthermore, e.g. various PU systems mayalso be used for the outer layer, for example two-component PU systems.PU systems are particularly well adaptable to different requirements.

The mentioned methods may also comprise a three-dimensionally moldingthe carrier material within the mold and/or using at least one of the atleast two mold parts. Thus, also the carrier material may bethree-dimensionally molded within the same apparatus—just as the innerand outer layer applied to the carrier material. For example, thecarrier material may be provided as a foil which is three-dimensionallymolded. Such foil may either be provided with or without textures andalternatively or additionally may be printed on. Moreover, it ispossible to provide the carrier material in flowable form, with thecarrier material then being three-dimensionally molded within the moldand subsequently being provided in solidified form. Thethree-dimensionally molding the carrier material may e.g. be carried outbefore the three-dimensionally molding the inner layer and/or before thethree-dimensionally molding the outer layer. The inner layer and/or theouter layer may then be molded on the three-dimensionally molded carriermaterial.

The provided carrier material may have a thickness of e.g. 0.05 mm to0.6 mm or 0.05 mm to 0.4 mm or approximately 0.1 mm or approximately 0.2mm. The carrier material may e.g. be provided as a foil, e.g. a plasticfoil, which e.g. comprises acrylonitrile butadiene styrene and/orthermoplastic polyurethane. The carrier material may also comprisepolyamide. A plastic foil may also comprise a base layer from thementioned materials, to which another layer is applied, which e.g.comprises thermoplastic polyurethane. The latter may be formed as adecoration layer and optically designed accordingly, e.g. printed on.The base layer and the decoration layer may each have a thickness of 1μm to 200 μm or 50 μm to 100 μm. Alternatively or additionally, thedecoration layer may be formed as a reflecting layer. Optionally, e.g.on the inner side, the carrier material may comprise a textile materialas a textile carrier. The textile material may, for example, be aknitted, weft-knitted, plaited and/or woven material and/or a non-wovenmaterial. Generally, it is also possible for the carrier material to beessentially entirely formed from a textile material. Moreover, thecarrier material may be designed such that it co-determines certainmechanical functions of the panel.

The three-dimensionally molding the carrier material may comprisesuctioning of the carrier material to at least one mold part. Thecarrier material may thus be three-dimensionally molded in accordancewith the mold part. For example, the carrier material may be sucked to amold part by applying negative pressure, e.g. to a second mold part usedtogether with the at least first mold part, and thus be pressed againstsaid mold part. In this regard, the carrier material may assume thetexture of the mold part used.

The three-dimensionally molding the carrier material may alternativelyor additionally also comprise pressing with a die element. For example,a second mold part used together with the at least first mold part maybe formed as a die element, which is pressed against the at least firstmold part. This way the carrier material may be three-dimensionallymolded in accordance with the shape of the die element and thecorresponding counter die.

Alternatively or additionally, the three-dimensionally molding thecarrier material may also comprise a deep-drawing the carrier materialinto the mold.

The three-dimensionally molding the carrier material may be carried outat a certain temperature and/or a certain temperature profile. Forexample, at least one of the mold parts of the mold may be heated orcooled. This way the three-dimensionally molding may be supported bytargeted heating or cooling of the carrier material, as alreadyexplained with regard to the inner and outer layer of the panel.

The described methods may also comprise printing on the carriermaterial. The printing may e.g. be carried out before providing thecarrier material within the mold. For example, the carrier material maybe provided as a printed foil. The carrier material may thus be used foroptically designing the panel in a desired manner. It is possible forthe carrier material to be printed on its outer side. When using an atleast partly transparent carrier material, however, the printing mayalso be carried out on its inner side.

The mentioned methods may further comprise creating textures on theouter side and/or on the inner side of the carrier material and/or anouter face and/or side faces of the outer layer. For example, texturesformed as pseudo-sutures and/or textures for increasing a staticfriction of the panel on the outer face of the outer layer may beprovided. Alternatively or additionally, textures on the carriermaterial may be provided for improving adhesion on the outer and/orinner layer formed thereon. Textures on the outer side of the carriermaterial and/or the outer face of the outer layer, however, mayalternatively or additionally also serve for creating optical effectswhich appear three-dimensional. Alternatively or additionally, texturesmay also be created on an inner face of the inner layer. These may e.g.increase the adhesion of the inner face on a bladder and/or a carcassfor a ball. A major advantage of the method according to embodiments ofthe invention is that any texture may be created completely within theused mold. Subsequent texturizing of the manufactured panels is notnecessary.

Textures may have a depth of approximately 0.01 mm-1.5 mm, but may alsoextend further in their length and/or width. A width of the textures maybe approximately 2.5 mm-3.5 mm. These dimensions are suitable forproviding desired aerodynamic and/or haptic properties. To provideaerodynamic properties, particularly a depth of 0.1 mm-1.5 mm is useful.To provide haptic properties, for example, a depth of 0.01 mm-0.1 mm isuseful.

Furthermore, textures may also comprise dimensions, in particulardepths, of less than 0.1 mm to influence the optical properties of thecarrier material and/or of the outer layer, for example by refraction oflight. This may particularly support providing effects which appearthree-dimensional. In this regard, e.g. upon incidence of light, achange in color of the outer layer may appear dependent on the depth ofthe respective textures. Moreover, textures may in different waysreflect, mirror, refract, scatter, etc. light impinging on the outerside of the carrier material and/or the outer layer.

The textures may be at least partly created by the mold comprisingcorresponding mold textures, e.g. indentations or protruding elements.For example, the textures may be created by the three-dimensionallymolding the respective element, i.e. the carrier material, the innerlayer and/or the outer layer. A separate working step for creating thetextures is therefore not necessary. The mold parts by means of whichthe respective inner or outer layer or optionally the respective carriermaterial is three-dimensionally molded may comprise corresponding moldtextures. Alternatively or additionally, textures may also at leastpartly be molded on the respective element by adding additional materialafter molding the respective element. Alternatively or additionally,textures may e.g. be created during the three-dimensionally molding byhigh-pressure molding, e.g. with a focused high-pressure gas jet.

According to an embodiment, a method for manufacturing a panel for aball, in particular for a soccer ball, comprises the following steps:three-dimensionally molding a carrier material having an outer side andan inner side within a mold having at least two mold parts;three-dimensionally molding an outer layer (or an inner layer) of thepanel on the outer side (or the inner side) of the carrier materialwithin the mold; three-dimensionally molding an inner layer (or an outerlayer) of the panel on the inner side (or the outer side) of the carriermaterial using at least one first of the at least two mold parts.

Another embodiment of the present invention relates to a panel for aball, in particular for a soccer ball, which is manufactured or may bemanufactured by means of one of the methods described herein.

Finally, another embodiment of the present invention relates to a ball,in particular a soccer ball, having a plurality of panels as describedherein.

Such a ball may comprise a bladder filled with air.

BRIEF DESCRIPTION OF THE FIGURES

Possible embodiments of the present invention are further described inthe following detailed description, with reference to the followingFigures:

FIG. 1 : An embodiment of a method for manufacturing a panel for a ball,in particular for a soccer ball;

FIG. 2 : A cross-section through an embodiment of a panel for a ball, inparticular for a soccer ball.

DETAILED DESCRIPTION OF THE INVENTION

It should be noted that only individual embodiments of the invention canbe described in greater detail below. However, the person skilled in theart recognizes that the design possibilities described in relation tothese specific embodiments may also be further modified and combineddifferently within the scope of the present invention and thatindividual features may also be omitted where they appear to bedispensable. In order to avoid redundancies, reference is particularlymade to the explanations in the previous sections, which also remainapplicable to the following detailed description. In particular,different of the aspects described in the following may be combined withthe aspects that were already explained.

FIG. 1 shows a schematic representation of a method for manufacturing apanel 10 for a ball, in particular for a soccer ball. In step 110, acarrier material 15 is provided within a mold. The carrier materialcomprises an outer side (arranged at the bottom in FIG. 1 ) and an innerside (arranged at the top in FIG. 1 ). The mold comprises a first moldpart 21 and a second mold part 22. In other examples, further mold partsand/or differently designed mold parts may be provided. In particular,the first and the second mold part may also be joined mechanically. Itis important for the mold parts to comprise mold surfaces 21 b, 22 barranged movably to each other. The mold parts may comprise exchangeableinserts, for example of silicone and/or ceramic and/or metal, by meansof which the mold parts may be modified. This way the cavities orindentations formed by the mold parts may be individually adapted.

According to FIG. 1 , the carrier material 15 is provided in an openedstate of the mold as a basically two-dimensional material within themold. For example, the carrier material 15 may be provided as a foil ora film. In other examples, however, the carrier material 15 may also beprovided as a different two-dimensional material; it may e.g. comprise atextile. It is also possible to use printed and/or otherwise opticallydesigned two-dimensional materials, e.g. on their outer side. Finally,the carrier material 15 may e.g. alternatively also be provided as aflowable or granular material, e.g. in the form of pellets, within themold.

In step 120, the provided two-dimensional carrier material 15 isoptionally three-dimensionally molded. The second mold part 22 may e.g.comprise openings 22 a, which may be formed as through holes or channelsand through which negative pressure may be provided such that thecarrier material is pressed to the second mold part 22. Already by thismeasure, the carrier material 15 may be molded three-dimensionally, e.g.according to the contours of the second mold part 22. Alternatively,openings, e.g. through holes or channels, may also be provided at thefirst mold part 21 for creating negative pressure. Alternatively oradditionally to applying negative pressure, the three-dimensionallymolding the carrier material 15 may also be achieved by pressing thecarrier material 15. For this purpose, e.g. the second mold part 22 maybe formed as a die element to press the carrier material 15 onto thefirst mold part 21. The three-dimensional shape of the carrier material15 is then basically determined by the cavity formed between the secondmold part 22 and the first mold part 21. This way e.g. also thethickness of the carrier material 15 may be changed. Thethree-dimensionally molding the carrier material 15 may also be carriedout without suctioning, e.g. in the case of providing the carriermaterial 15 as a flowable or granular material. In this case, theflowable material may be solidified during the three-dimensionallymolding the carrier material 15.

According to FIG. 1 , the carrier material 15 is three-dimensionallymolded such that it comprises at its inner side an indentation intowhich material for an inner layer may be introduced later.

The three-dimensionally molding the carrier material 15 may beoptionally supported by being carried out at a certain temperature. Forexample, the second and/or the first mold part may be heated or cooledto a certain temperature. If desired, the temperature profile may becontrolled during heating and/or or cooling the carrier material 15.

The first mold part 21 and/or the second mold part 22 may optionallycomprise mold textures such that corresponding textures may be createdin the pressed-on carrier material 15. For example, on the surface ofthe carrier material, elevations and/or indentations may be created.These may comprise the already mentioned dimensions. Such textures maye.g. improve bonding of an inner or outer layer of the panel to thecarrier material. Moreover, such textures may be used for creatingeffects which appear three-dimensional on the outer side of the panel—incombination with an at least partly transparent outer layer.

In other examples, the carrier material 15 may be provided within themold already three-dimensionally pre-molded and/or already havingtextures.

In step 130, material for an outer layer 14 of the panel 10 isintroduced into the mold through one or more openings 21 a of the firstmold part. More precisely, the material is introduced into a cavityformed by the first mold part 21 and the second mold part 22 and appliedto an outer side of the carrier material 15. The material may be cast orinjected into the opening 21 a in an e.g. flowable state. In otherexamples, the material for the outer layer 14 may also be otherwiseintroduced into the mold. For example, the second mold part 22 mayalternatively or additionally to the first mold part 21 comprise one ormore corresponding openings. However, the material may also be cast orotherwise introduced into the mold in an open state of the mold suchthat the mold parts do not necessarily have to comprise openings.

By the cavity formed between the first mold part 21 and the second moldpart 22, the three-dimensional shape of the outer layer 14 may bepredetermined such that the outer layer 14 may be three-dimensionallymolded. The outer layer 14 may, as shown in FIG. 1 , be completelyarranged around the outer side of the carrier material 15 such that theouter side is completely protected by the outer layer 14. The outerlayer 14 may be basically provided with even thickness. However, it isalso possible to design the thickness of the outer layer 14 to vary.

According to FIG. 1 , in steps 120 and 130 the same mold parts 21 and 22are used. In other examples, the first mold part 21 used in step 120 maybe replaced with another first mold part for step 130.

As already explained, textures may be created on the outer side of theouter layer 14. Said textures may be formed to improve the aerodynamicand/or haptic (e.g. static friction) and/or optical properties of thepanel. The textures may be created e.g. by corresponding mold textureswithin the at least one first mold part 21. If desired, by means ofthese mold textures, corresponding textures in the carrier material 15may already be created in step 120.

In step 140, the second mold part 22 is replaced with a third mold part23 having a mold surface 23 b. The first mold part 21 used for moldingthe outer layer, however, remains a part of the mold. Alternatively,second mold part 22 may be used. It may e.g. comprise plural moldsurfaces 22 b such that the same second mold part 22 may be used as amold part in a different way. It is important that the carrier material15 and the outer layer 14 formed thereon may remain within the firstmold part 21, in particular its mold surface 21 b, used for thethree-dimensionally molding the outer layer 14, such that the workpiecedoes not need to be removed from the mold.

In step 150, material for an inner layer 16 of the panel 10 isintroduced into the cavity formed by the first mold part 21 and thethird mold part 23 and applied to an inner side of the carrier material15 which has remained within the first mold part 21. The inner layer 16is three-dimensionally molded in accordance with the cavity formed bythe first mold part 21 and the third mold part 23 on the inner side ofthe carrier material 15. Also during this process, the at least onefirst mold part 21 and/or the at least one third mold part 23 may, asdescribed with respect to the molding of the outer layer 14 and the moldparts 21, 22, be optionally heated and/or cooled.

The material for the inner layer may—as explained with respect to thematerial for the outer layer—be introduced into the mold e.g. in aflowable and/or granular state. For this purpose, e.g. the third moldpart 23 may comprise one or more openings 23 a through which thematerial is cast or injected. It is also possible to introduce thematerial for the inner layer 16 into the mold e.g. through openings inthe form of pellets, e.g. pellets of expanded thermoplasticpolyurethane. The pellets may e.g. be compounded into a homogenous foamby adding water vapor and/or heat, as e.g. described in DE 10 2012 206094 and EP 2 649 896. For this purpose, the first mold part 21 and/orthe third mold part 23 may comprise corresponding openings.

In other examples, the material for the inner layer 16 may also beotherwise introduced into the mold. For example, the first mold part 21may alternatively or additionally to the third mold part 23 comprise oneor more corresponding openings. However, the material may also be castor otherwise introduced into the mold in an open state of the mold suchthat the mold parts do not necessarily have to comprise openings.

The inner layer 16 may, as e.g. shown in FIG. 1 , may close anindentation formed by the inner side of the carrier material 15. Thus, apanel 10 may be provided, which is enclosed by the outer layer 14 andthe carrier material 15 at its outer face and at its side faces, whereinthe panel simultaneously comprises a back surface which is flat or e.g.evenly curved (for example corresponding to a curvature of the ball forwhich the panel is intended). As explained with regard to the outerlayer 14, also inner layer 16 may be provided with a same or varyingthickness.

Also third mold part 23 may optionally comprise mold textures such thatcorresponding textures may be created at the inner face of the innerlayer 16. Such textures may e.g. improve adhesion of the inner layer ona bladder and/or a carcass for a ball.

Generally, it is also possible to mold further layers onto the panel 10after the three-dimensionally molding the inner layer 16. For example,it is conceivable to replace the third mold part 23 with a fourth moldpart. The first mold part 21 may remain a part of the mold.Alternatively, also third mold part 23 may be used to mold furtherlayers. Generally, an additional inner layer could be injected ontoinner layer 16 this way.

In step 160, the manufactured panel 10 is removed from the mold.Optionally, the finished panel 10 may be deburred.

A plurality of panels 10 manufactured this way may be arranged on aninflatable bladder for a ball provided with adhesive. For example, thebladder may be sprayed with a suitable glue. The adhesive may be curedby means of heat treatment such that a finished ball with a bladder anda plurality of (e.g. three or more) panels is provided.

FIG. 2 shows a schematic representation of a cross-section through apanel according to an embodiment of the present invention. The panelcomprises a carrier material 220 and an outer layer 210 as well as aninner layer 230, which may be manufactured as already explained.

In particular, the outer layer 210 may be at least partly transparent.The at least partly transparent outer layer 210, however, maysimultaneously comprise a certain coloring. On the outer side of theouter layer 210 textures 212 may be provided, which may serve for thealready-explained purposes. The textures 212 may be created during thethree-dimensionally molding the outer layer 210 and basically comprisethe same material as a homogenous base layer 211 of the outer layer 210arranged under the textures, as already explained with regard to FIG. 1. However, it is also possible to apply the textures from a thin layerfrom another material onto the base layer 211 of the outer layer 210.The material of the base layer 211 and the textures 212 may e.g. merelydiffer in coloring. Alternatively or additionally, the same material maybe used, e.g. polyurethane, but with a different degree of hardness.However, it is also possible to use completely different materials. Thethree-dimensionally molding the outer layer may e.g. be designed as amethod with two or more steps, wherein the material for the base layer211 or the textures 212 is successively three-dimensionally molded.

Also the carrier material 220 may, as already explained, at its innerand/or outer side comprise textures 222, which may be created asexplained with reference to FIG. 1 and may serve for thealready-mentioned purposes. The textures 222 of the carrier material220, however, may also be manufactured analogously as described withregard to the textures 212 of the outer layer 210. For example, they maybe created during three-dimensionally molding the carrier material 220and they may be composed of a different material than a base layer 221of the carrier material 220. The three-dimensionally molding the carriermaterial may be accordingly designed in two or more steps.

According to FIG. 2 , textures 222 are, by way of example, merelyprovided at the outer side of the carrier material 220. The material forsuch textures 222 of the carrier material 220 may e.g. be at leastpartly transparent. The base layer 221 of the carrier material 220 maye.g. be printed on or otherwise optically designed. Also the textures222 of the carrier material 220 may be accordingly optically designed;they may e.g. be imprinted into the base layer 221 of the carriermaterial 220 such that they basically have the same color design as thebase layer 221 of the carrier material. By combining the optical designof the carrier material 220 and/or its textures 222 with the transparentouter layer 210, which is optionally provided with a coloring, and/orthe textures 212 of the outer layer 210, multiple options for opticallydesigning the panel are provided; in particular, effects which appearthree-dimensional may be created, as already explained.

Also the inner layer 230 may comprise a particular coloring and may—incombination with an at least partly transparent carrier material220—also contribute to optically designing the panel.

What is claimed is:
 1. A panel for a ball, the panel comprising: aninner layer having a planar structure, the inner layer comprising aninner face, an outer face, and side faces, wherein the inner layer is athree-dimensionally molded layer; an outer layer, wherein the outerlayer is a three-dimensionally molded layer; a structure elementembedded within the outer layer such that the outer layer surrounds thestructure element, wherein the structure element comprises at least oneof a knitted fabric, a weft-knitted fabric, a warp-knitted fabric, amesh, or a woven fabric; and a carrier material disposed between theinner layer and the outer layer, wherein the carrier material entirelyencloses the outer face and side faces of the inner layer, wherein theinner face of the inner layer is configured to contact a bladderdisposed in the ball and comprises a textured surface that is configuredto promote adhesion between the inner face of the inner layer and thebladder.
 2. The panel of claim 1, wherein the outer layer comprises: afirst layer comprising a surface that interfaces with the carriermaterial; and a second layer.
 3. The panel of claim 2, wherein thesecond layer comprises a textured surface.
 4. The panel of claim 2,wherein the second layer comprises a transparent material, thetransparent material being configured to prevent abrasion of the panel.5. The panel of claim 1, wherein the inner layer and the outer layereach comprise a polyurethane.
 6. The panel of claim 5, wherein thepolyurethane is a foamed polyurethane or a thermoplastic polyurethane.7. The panel of claim 1, wherein the carrier material comprises atextured surface that is configured to promote adhesion between thecarrier material and the inner layer and the outer layer.
 8. The panelof claim 1, wherein the panel is resistant to abrasion and wrinkling. 9.The panel of claim 1, wherein thermal energy is used to bond the innerlayer to the carrier material and the outer layer to the carriermaterial.
 10. A ball, comprising: a plurality of panels defining theouter surface of the ball, wherein a panel comprises: an inner layer,wherein the inner layer is a three-dimensionally molded layer; an outerlayer comprising an outer side defining at least a portion of the outersurface of the ball, wherein the outer layer is a three-dimensionallymolded layer, wherein the outer layer comprises a texture in the outerside, and wherein the texture has a depth of about 0.01 mm to about 1.5mm; a carrier material disposed between the inner layer and the outerlayer, wherein the carrier layer comprises an inner side defining anindentation configured to receive the inner layer such that the innerside of the carrier layer entirely encloses an outer face of the innerlayer and side faces of the inner layer, and wherein the carrier layercomprises an outer side in contact with the outer layer; and a structureelement embedded within the outer layer such that the outer layersurrounds the structure element, wherein the structure element comprisesat least one of a knitted fabric, a weft-knitted fabric, a mesh, or awoven fabric; and a bladder disposed under the plurality of panels,wherein at least one of the inner side of the carrier material or theouter side of the carrier material comprises a textured surface thatpromotes adhesion to the inner layer or the outer layer.
 11. The ball ofclaim 10, wherein the carrier material further comprises a textilematerial, the textile material comprising at least one of a knittedfabric, a weft-knitted fabric, a plaited fabric, a woven material, or anon-woven material.
 12. The ball of claim 10, wherein an inner side ofthe inner layer comprises a textured surface that promotes adhesionbetween the inner side of the inner layer and the bladder.
 13. The ballof claim 10, wherein the carrier material comprises: a first layercomprising a polymeric foil; and a second layer.
 14. The ball of claim13, wherein the foil comprises at least one of acrylonitrile butadienestyrene, a thermoplastic polyurethane, and a polyamide.
 15. The ball ofclaim 14, wherein the second layer comprises a thermoplasticpolyurethane.
 16. The ball of claim 14, wherein the second layer is areflecting layer.
 17. The ball of claim 10, wherein the carrier materialhas a thickness of between 0.05 mm and 0.2 mm.
 18. The ball of claim 10,wherein the plurality of panels are secured to the bladder by anadhesive.
 19. The ball of claim 18, wherein the adhesive is cured byheat treatment.
 20. The ball of claim 10, wherein each of the pluralityof panels comprises: an inner layer; an outer layer; and a carriermaterial disposed between the inner layer and the outer layer, thecarrier layer comprising an inner side in contact with the inner layerand an outer side in contact with the outer layer.
 21. The ball of claim10, wherein the inner side comprises a textured layer that promotesadhesion to the inner layer, and the outer side comprises a texturedsurface that promotes adhesion to the outer layer.
 22. A panel for aball, the panel fabricated by a method comprising: providing a carriermaterial having an outer side and an inner side within a mold having atleast one first mold part and at least one second mold part;three-dimensionally molding an outer layer of the panel on the outerside of the carrier material within the mold such that a structureelement is embedded within and surrounded by the outer layer, whereinthe structure element comprises at least one of a knitted fabric, aweft-knitted fabric, a warp-knitted fabric, a mesh, or a woven fabric;three-dimensionally molding an inner layer of the panel on the innerside of the carrier material using at least the first mold part suchthat the carrier material entirely encloses an outer face and side facesof the inner layer; and creating a texture on an inner face of the innerlayer so as to aid adhesion of the inner face to a bladder to bedisposed in the interior of the ball.
 23. A ball comprising a pluralityof panels according to claim 22, wherein the ball is a soccer ball. 24.The panel of claim 1, wherein the outer layer comprises: a first layercomprising a surface that interfaces with the carrier material; and asecond layer, the second layer comprising a transparent materialconfigured to prevent abrasion of the panel, wherein the inner layer andthe outer layer each comprise a foamed polyurethane or a thermoplasticpolyurethane.
 25. The ball of claim 10, wherein the outer layercomprises a transparent portion, and wherein the carrier materialcomprises a reflecting portion.
 26. The method of claim 22, wherein theouter side of the carrier material comprises a reflective portion, andwherein the inner side of the carrier material comprises a textilematerial.
 27. The ball of claim 10, wherein the texture in the outerside of the outer layer is defined by indentations or protrusions havinga width of about 2.5 mm to about 3.5 mm.
 28. The ball of claim 27,wherein the texture in the outer side of the outer layer has a depth ofabout 0.01 mm to about 0.1 mm.